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Detergent Powder

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Submitted By muzzaffariqbal
Words 1537
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Detergent Powder Plant

Introduction

Spray Drying
Soapergent Industry company specializing in the development, design and engineering of liquid and powder processing equipment for the manufacture of products in liquid, powder, granular or agglomerate form. Spray dryers and coolers, fluid bed systems, evaporators, homogenizers, And granulators.

Today’s plants are designed for operational and environmental safety, featuring concepts that give the lowest energy consumption, while achieving the highest product qualities.

Spray dryers for the production of:

Agro- chemicals Ceramics
Coffee Dairy products
Detergents Dyestuffs
Enzymes Fine/ bulk chemicals
Flavors Foodstuffs
Mineral concentrates Pharmaceuticals
Polymers Proteins
Effluents Sludges

Process
Spray drying is the most widely used industrial process involving particle formation and drying. It is highly suited for the continuous production of dry solids in either powder, granulate or agglomerate form from liquid feed stocks as solutions, emulsions and pumpable suspensions. Therefore, spray drying is an ideal process where the end product must comply with precise quality standards regarding particle size distribution, residual moisture content, bulk density, and particle shape. Spray drying involves the atomization of a liquid feedstock into a spray of droplets and contacting the droplets with hot air in a drying chamber. The sprays are produces by either rotary (wheel) or nozzle atomizers. Evaporation of moisture from the droplets and formation of dry particles proceed under controlled temperature and airflow conditions. Powder is discharged continuously from the drying chamber. Operating conditions and dryer design are selected according to the drying characteristics of the product and powder specification.

Principles
Every spray dryer consists of feed pump, atomizer, air heater, air disperser, drying chamber, and systems for exhaust air cleaning and powder recovery. Widely varying drying characteristics and quality requirements of the thousands of products spray dried determine the selection of the atomizer, the most suitable airflow pattern, and the drying chamber design. Atomization The formation of sprays having the required droplet size distribution is vital to any successful spray dryer.

Atomization is a high technology area where Soapergent Dryer Industry has played a central role in the development and use of nozzles and rotary atomizers in spray drying.

Airflow the initial contact between spray droplets and drying air controls evaporation rates and product temperatures in the dryer. There are three modes of Contact:

Co- current
Drying air and particles move through the drying chamber in the same direction. Product temperatures on discharge form the dryer are lower than the exhaust air temperature, and hence this is an ideal mode for drying heat sensitive products. When Operating with rotary atomizer, the air disperser creates a high degree of air rotation, giving uniform temperatures throughout the drying chamber. However, an alternative non- rotating airflow is often used in tower or Filtermat- type spray dryers using nozzle atomizers with equal success.

Counter- current
Drying air and particles move through the drying chamber in opposite directions. This mode is suitable for products, which require a degree of heat treatment during drying. The temperature of the powder leaving the dryer is usually higher than the exhaust air temperatures.

Mixed flow
Particle movement through the drying chamber experiences both co- current and counter- current phases. This mode is suitable for heat stable products where coarse powder requirements necessitate the use of nozzle atomizers, spraying upwards into an incoming airflow, or for heat sensitive products where the atomizer sprays droplets downwards towards an integrated fluid bed and the air inlet and outlet are located at the top of the drying chamber.

Spray Dryer Chamber Design
As drying characteristics and product specifications vary from product to product, there is no one spray drying chamber design suitable for all applications. By offering a full range of designs, Soapergent Dryer Industry impartially selects the most suitable type of plant.

Spray Drying Systems
The essential elements of the spray dryer: atomizer, air disperser, drying chamber, inlet and exhaust air handling are combined into a system that meets individual operational safety, environmental protection, and powder handling requirements. All systems can be provided with post- treatment equipment: fluid bed dryer/cooler, agglomerator, de-duster and conveyor.

Open
Featuring once- through airflow with exhaust to atmosphere. The majority of industrial spray dryers handles aqueous feedstocks and uses this system. Both direct and indirect airheating are applicable. Exhaust air cleaning in cyclones, bag filters, electrostatic precipitators, and scrubbers.

Closed cycle
Featuring drying in an inert gas atmosphere where nitrogen recycles within the dryer. This system must be used for the sprat drying of feedstocks containing organic solvents or where the product must not contact oxygen during drying. Closed cycle plants are gas and powder tight, and are designed to the strictest safety standards. The inflammable solvent vapours are fully recovered in liquid form.

Semi-closed cycle
Featuring either the partial recycle mode (recycle of up to 60% of the exhaust air as inlet air to the dryer, for effective waste heat utilization) or the self- inertizing mode, where direct air heating and a minimal air bleed create the low oxygen atmosphere necessary for drying aqueous feedstocks that form explosive powder-air-mixtures. If odour is generated during drying, the small volumes of air vented from the system can be effectively and economically incinerated.

Aseptic
Featuring sterile feed atomization and air filtering systems. These dryers are used where any form of powder contamination must be avoided. They are fabricated to special standards of finish and operate under a slight pressure. Fully automatic cleaning and sterilization systems are available. Plant layout is integrated with thelaminar flow packing room.

Features to meet special design specifications
Air dispersers for rotary and nozzle atomizer assemblies Pressure shock resistant drying chambers with venting or suppression for explosion protection

Semi- or fully automatic cleaning systems (CIP)
Components designed to international sanitary standards
Conventional or computerized control systems
Air/air or air/liquid/air waste heat recovery units
Air- broom and air-sweep attachments for drying chamber
Noise attenuation of components
Weatherproof finish for outdoor installations
Rotary atomizers with inert gas purging
Semi- or fully automatic solvent cleaning systems
Gas tight: package plant test erected prior to shipment
Available with cyclones or bag filters
Condenser systems to +/-30°.

Atomizers
Three types of atomizers are used in industrial drying:
Rotary
Atomization by centrifugal energy
Pressure nozzle
Atomization by pressure energy
Two-fluid nozzle
Atomization by kinetic energy

The choice of atomizer depends upon the properties of the feed and dried product specification. In cases where more than one atomizer type is suitable, the rotary atomizer is generally preferred due to its greater flexibility and ease of operation. The advantages include:

Handling of high feed rates without need for atomizer duplication
Handling of abrasive feeds
No blockage problems
Low pressure feed system
Ease of droplet size control through wheel speed adjustment rates up to 200t/h and power requirements up to 800kW.

Spray Dryers for Industrial Production

Food and Dairy Industry
Foodstuffs and dairy products in powder or agglomerate form:

• Baby food Cheese/ whey products • Coconut milk Coffee/ coffee substitutes • Coffee whitener Eggs • Flavours Maltodextrine • Mild Soup mixes • Soy- based food Spices/ herb extracts • Sugar-based food Tea • Tomato Vegetable protein

Spray drying is ideal for these heat sensitive products, where selection of system an operation is the key to high nutritive and quality powders of precise specification. “Instant”, highly soluble powders are a speciality of spray dryers featuring integrated belts or fluid beds. All components in contact with product comply with hygienic processing standards. Today’s plants have special sanitary features, automatic cleaning (CIP) and bagging-off systems.
Associated equipment includes agglomerators, evaporators, freeze concentrators, homogenizers, lecithination units and powder blenders.
Complete processing lines for instant coffee, coconut milk, baby food and dairy products are part of the SoapTech Dryer Industry delivery programme.

Chemical Industry
Specialty chemicals:

• Detergents Dyestuffs • Fine organic/inorganic chemicals Agro- chemicals • Chelates Fungicides • Herbicides Insecticides • Silicates

Spray dryers for the chemical industries produce a variety of powdered, granulated and agglomerated products in systems that minimize formation of gaseous, particulate and liquid effluents.
High efficiency scrubber systems and high performance bag filters prevent powder emission, while recycle systems eliminate problems of handling solvents, product toxicity, and fire explosion risks. Special component designs (e.g. atomizers) are available for abrasive and corrosive feedstocks. High thermal efficiencies, low maintenance costs, full environmental protection, computerized control, dust-free working area are some of the features of today’s spray dryers.

.

Service to Industry
Product testing and process evaluation
Design and engineering
Plant delivery, erection and commissioning
Establishing a close collaboration wit customers secures successful spray dryer operation in the shortest possible time.
Product testing and process evaluation

Design and engineering
With process data confirmed during testwork, the spray dryer is specified and designed based upon the latest technology and industrial experience. The most modern design aids are used. Operation and maintenance manuals are individually prepared for each project.

Fabrication
Components are fabricated by selected subsuppliers, whereas rotary atomizers are manufactured in Soapergent Dryer Industry own workshop.

Plant delivery, erection, and commissioning
Punctuality of delivery is essential to today’s business, and Soapergent Dryer Industry is known for plant delivery on time. Responsibility for total plant erection is accepted, and site erection supervision can be supplied. The company’s own engineers are present during the commissioning phase.
A round-the-clock spare parts service is maintained.

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